Challenge
Thermal deformations and their effects on precision
Thermal deformation is one of the greatest challenges in modern machine tools. The thermal behavior of the headstock and other machine components can lead to geometric deviations that significantly impair machining accuracy. Especially in high-precision manufacturing processes, this means potential quality degradation, scrap, and rework—and thus economic losses. Conventional cooling and temperature control strategies often reach their limits here. The solution? Predictive compensation of thermal effects using digital simulation technologies.
Application
Real-time simulation to compensate for thermal influences
To compensate for thermally induced displacements, a reduced order model (ROM) is used. This model is based on a detailed FEM simulation of the heat distribution and deformations of the machine, but has been optimized to perform calculations in real time. Integration into the machine control system enables precise adjustment of the tool path, process parameters, and cooling strategies. Thanks to temperature measurements on the machine and the consideration of environmental influences, the control system can react proactively before any loss of precision occurs.
Advantages
Higher precision, lower costs, more efficient processes
The use of modern simulation technologies brings decisive competitive advantages for machine manufacturers and operators:
- Increased manufacturing accuracy: Precision losses due to heat are automatically compensated.
- Reduced production costs: Less scrap and rework significantly reduce operating costs.
- Optimized process stability: Adaptive control and real-time correction improve the overall performance of the machine.
- Faster market launch of new machines: Manufacturers can use simulation models during the development phase to take thermal effects into account at an early stage.
With simulation technologies, we're setting new standards in digital manufacturing. Are you ready to take your machines to the next level? 🚀